Assembling electrical components

ABSTRACT

A plurality of strips of repetitively configured partially formed and interconnected blade-like terminals are indexed along predetermined paths which extend through passageways in a shearing assembly and into grooves of a stationary die block which are aligned with the passageways. The leading repetitively configured portion of each of the strips is received in the associated groove such that the leading portions are each supported along a leading edge and two adjoining flat faces. The shearing assembly is moved in a direction extending between the faces to separate the leading portion from the remainder of each strip and thereby form a plurality of terminals. The shearing assembly has the dual function of covering the grooves following the separation of the leading portions to provide support for the trailing edge of each leading portion as formed during separation. Insertion facilities are operated to move the terminals from the grooves and into associated ones of a plurality of terminal-receiving openings formed in a miniature type telephone cord plug prepositioned in alignment with the insertion facilities.

United States Patent [1 1 Brown, deceased et al.

[111" I 3,839,787 [451 Oct. 8,1974

[ ASSEMBLING ELECTRICAL COMPONENTS [75] Inventors: William B. Brown, deceased, late of Pasadena, Md. by Hazel V. Brown, representative; Frederick David Gavin, Baltimore, Md.

[73] Assignee: Western Electric Company, Inc.,

New York, NY.

[22] Filed: Mar. 30, 1973 [21] Appl. No.: 346,556

[52] US. Cl. 29/629, 29/203 R, 29/203 P [51] Int. Cl, H02g 15/00 [58] Field-of Search 29/628, 629, 203 R, 203 P;

[56] References Cited UNITED STATES PATENTS 2,613,432 10/1952 Gilbert 29/206 3,341,926 9/1967 Durr 8! 3|. 3,641,646 2/1972 Folk 3,669,332 6/1972 Berg 227/95- Primary Exa mineF-C. W. Lanham Assistant Examiner-James R. Duzan Attorney, Agent, or Firm-E. W. Somers [5 7] ABSTRACT A plurality of strips of repetitively configured partially formed and interconnected blade-like terminals are indexed along predetermined paths which extend through passageways in a shearing assembly'and'into grooves of a stationary die block which are aligned with the passageways. The leading repetitively configured portion of each of the strips is received in-the associated groove such that the leading portions are each supported along a leading edge and two adjoining flat faces. The shearing assembly is moved in a direction extending between the faces to separate'the leading portion from the remainder of each strip and thereby form a plurality of terminals. The shearing assembly has the dual function of covering the grooves following the separation of the leadingportions to pro-- vide support for the trailing edge of each leading portion as formed during separation. Insertion facilities are operated to move the terminals from the grooves and into associated ones of a plurality of terminalreceiving openings formed in a miniature type telephone cord plug prepositioned in alignment with the insertion facilities.

9 Claims, 11 Drawing Figures PATENTEB 31974 3.839.787

sum 30? 5 PATENTED "E l974 METSBF 5 1 ASSEMBLING ELECTRICAL COMPONENTS BACKGROUND OF THE INVENTION apparatus for assembling a plurality of flat blade-like terminals to a dielectric body to form a plug which is connected to each end of a telephone cord for use with customer telephone equipment.

2. Technical Considerations and the Prior Art Recent advances in the facilities which are provided in the homes of telephone subscribers includes a miniature connector which is attached to bothends of a tele-v phone cord. The connector is designed to facilitate attachment of the cord to the telephone equipment by the subscriber. Such a miniature plug is disclosed and claimed in U.S. Pat. No.- 3,699,498, issued on Oct. 17, 1972 in the names of E. C. Hardesty, Charles L. Krumreich, A. E. Mulbarger, .lr.,,and S. W. Walden. An improved version of the miniature plug is disclosed and claimed in co-pending application Ser; No. 232,803 filed on Mar. 8, 1972 in the names of E. C. l-lardesty, C. L. Krumreich, A. E. Mulbarger, Jr., and S. W. Walden.

A plurality of terminals which are flat and blade-like are inserted into associated grooves formed in a dielectric body to which a telephone cord has been priorly attached. The insertion of the terminals into the dielectric body causes contact tangs formed on the terminals to make electrical engagement with associated ones of the cord conductors.

' As may be appreciated from the above-identified 'pa- 1 tent, the terminals which are inserted into a dielectric body of the plug have very small dimensions. For example, the terminals may be approximately 0.134 inch stresses. Should the terminals undergo undesired stresses, the terminals may become distorted and cause problems when attempting to insert them into the plug.

The prior art includes methods and apparatus for inserting terminals into dielectric bodies. For example, reference may be made to U. S. Pat. No. 2,613,432 in which is shown a machine for assembling the well known plugs used for household electrical appliances. Contact elements made of a suitable conductingmaterial are retroflexed to form a two-legged element adapted to be inserted into a dielectric body. Two strips of the contact elements which are separated except for a slight interconnecting piece of metal are advanced along inclined guideways toward each other and a reciprocally moveable punch. The punch is operated to shear a leading one of each of the contact elements from the associated strip. The elements are pushed downwardly by shoulders formed on the punch. Simultaneously a sliding wedge device aligned with a dielectric plug is moved inwardlysuch that spring-biased dogs on the wedge device operate to push the two spaced contact elements individually under overhanging edges of the guideway. The overhanging edges function to form with the walls thereof guiding grooves in which the contact elements are subsequently caused to travel towards the plug body during the next forward movement imparted to the wedge device. As the wedge device is advanced toward the plug, shoulders formed on the spring-biased dogs engage ends of the contact elementsuto move the contact elements forwardly towards the plug body for insertion thereinto.

The foregoing apparatus deals with electrical connectors of substantially larger size than those which are contemplated with the. instant invention. Moreover, the punching device shears the leading ones of the two terminal strip with a separate inserter or wedge device partially completing a guideway for each of the contact elements which falls into the guideway.

Because of the frailty of the terminals involved in the miniature connector, it isimperative that the insertion thereof limit the movement of the individual terminals to avoid any distortion of the terminals or damage to the contact tangs thereof.

SUMMARY OF THE INVENTION The present invention contemplates the assembling of a first part with a second part by advancing a repetitively configured elongated material along a predetermined path to move a leading portion'thereof through a passageway opening to one surface and then into a groove opening into another surface adjacent to the one surface such that the leading portion is supported along a leading edge and two adjoining faces. Then relative movement is caused to occur between the two surfaces in a direction extending between the two faces to separate the leading portion of the elongated material and to form a'first part while simultaneously covering the groove to complete the support of the formed first part around the periphery thereof. The periphery thereof is in a plane defined by the predetermined path and the directionof movementbetween the two surfaces. Then the second partis aligned with the groove. An unsupported surface of the formed first part isengaged and the formed first part is moved from the groove and into assembled relationship with the aligned second part. More particularly, methods and apparatus are provided for assembling blade-like terminals with a dielectric body to form an electrical connector having miniature dimensions. Strips of a repetitively configured elongated metallic material are fed along a path after which a leading portion of each of the strips of the elongated material is enclosed partially laterally. Then the leading portions of the elongated material are separated from the remainder of the strips of elongated material between ones of repetitive configurations thereof to form a plurality of terminals. The separation is accomplished while simultaneously completing the lateral enclosure of the formed terminals to form passageways for the terminals which are aligned with a portion of the dielectric body to which the terminals are to be assembled. Then an exposed unsupported surface of each of the terminals is engaged and the terminals moved along the passageways intoassembled relationship with the dielectric body to form the electrical connector.

BRIEF DESCRIPTION OF THE DRAWINGS Other features of the present invention will be more readily understood in the following detailed description of specific embodiments thereof when read in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of a miniature plug-in connector which is attached to each end of a telephone cord for attachment to subscribers telephone equipment and which shows terminals which are to be inserted into the plug to form the connector;

FIG. 2 is a perspective view of an overall apparatus embodying the principles of this invention and used to insert the terminals into dielectric bodies preconnected to each of two telephone cords to form electrical connectors;

FIG. 3 is a perspective view, partially in section, showing the highlights of the left hand portion of the apparatus of FIG. 2 for accomplishing the forming and the insertion of the terminals into one of the plugs preconnected to one end of a retractile cord;

FIG. 4 is a view in elevation and partially in section showing a strip of partially formed terminals being advanced along a guideway, then through a shearing assembly and into a groove in a die block in alignment with an insertion tool for inserting the terminals into the dielectric body to form the electrical connector;

FIG. 5 is a front elevational view of the assembly which is used to shear the leading one of the terminals from each of the strips thereof to form a blade-like terminal;

FIG. 6 is a side view in section of the shearing assembly and associated insert shown in FIG. 5;

FIGS. 7A and 7B are a sequence of views in section showing the steps in forming and supporting com- I pletely laterally leading ones of the terminals which are to be inserted into the connector;

FIG. 8 is a perspective view showing the position of the grooves in the die block and the passageways in the shearing assembly after the shearing assembly has been moved with respect to the die block; and

FIGS. 9A and 9B are a sequence of views showing the movement of the formedterminals along the grooves and into electrical engagement with the conductors of the cord.

DETAILED DESCRIPTION Description of Connector Referring now to FIG. 1 there is shown a connector, designated generally by the numeral 20, and which includes a mating housing 21 and cover 22. The mated housing 21 and cover 22 form a dielectric body, designated generally by the numeral 23. A cord 24, having a plurality of conductors 25-25, is positioned between the housing 21 and the cover 22 prior to the mating thereof. The conductors 25-25 are received in individual conductor-receiving troughs (not shown) for subsequent connection to associated ones of a plurality of terminals 26-26.

Each of the terminals 26-26 has contact tangs 27-27 formed thereon. The contact tangs 27-27 engage with the associated ones of the conductors 25-25 when the terminals 26-26 are inserted into associated grooves 28-28 formed in the dielectric housing 21. Moreover, the terminals 26-26 are designed such that when the terminals are inserted into the grooves 28-28, the terminals seat therewithin and lock in the grooves of the dielectric housing 21.

The miniature connector plug 20 also includes a ledge 29 which is used as a back-up surface'for cutting off those portions of the conductors 25-25 which extend beyond the troughs (not shown).

OVERALL DESCRIPTION OF THE APPARATUS Referring now to FIG. 2 there is shown an apparatus, designated generally by the numeral 30, for forming and for assembling the terminals 26-26 with two di electric bodies 23-23, each of which is pre-assembled to one end of a retractile cord 24. Feeding facilities, designated generally by the numeral 31, are provided for feeding a plurality of strips 32-32 of partially formed terminals 26-26 into engagement with a terminal-forming and insertion apparatus, designated generally by the numeral 33. The terminal forming and insertion apparatus 33 includes facilities for receiving the leading portion of each of the repetitively configured strips 32-32 of partially formed terminals 26-26 and for then shearing the leading portion therefrom. The leading portion of each of the strips 33-33, which is formed into'one of the terminals 26-26, is supported around a defined periphery thereof.

Each of the plug-ends of the cords 24-24 is positioned in a cavity 34. Then, each of the newly formed terminals is engaged by the insertion portion of the facilities 33, for movement into engagement with an associated ones of the grooves 28-28in the housing 21 of the dielectric body 23 which have been prepositioned in the cavities 34-34 of the insertion facilities.

FEEDlNG FACILITIES As can be seen in FIG. 2, facilities 31 are provided for feeding a plurality of repetitively configured strips 32-32 into engagement with the terminal forming'and insertion apparatus 33. The facilities include two 1 groups of four rolls 36-36 of the strips 32-32 supported in suitable bearings (not shown). Each of the strips 32-32 includes a plurality of partially formed terminals 26-26 interconnected by thin strips 37-37 of metallic material (see FIG. 3).

Each of the strips 32-32 is pulled from an associated one of the rolls 36-36 and advanced between cooperating guide rollers 38-38 (see FIG. 2). The rollers 38-38 are mounted rotatably on a shelf 39 about axes generally horizontally disposed. As the strips 32-32 are pulled from the rolls 36-36 and advanced between the sets of cooperating guide rollers 38-38, the strips are oriented with the flat faces thereof essentially parallel to the top of the support shelf 39.

From there, the four strips 32-32, associated with each half of the apparatus 30, are advanced toward a common feed-in point between a plurality of sets of rollers 41-41. The rollers 41-41 are mounted rotatably on an extension 42 of a platform 43. Each of the strips 32-32 is advanced between at least two sets of cooperating ones of the rollers 41-41.

While the rollers 38-38 are mounted rotatably about axes which are parallel to the axes of rotation of the rolls 36-36, the axes of rotation of the rollers 41-41 are generally perpendicular thereto. It can be seen in FIG. 2 that as the strips 32-32 are advanced between the rollers 41-41, the strips are turned so that the flat faces thereof are generally parallel to the axes of the rollers 41-41. In this way, the strips 32-32 are oriented so that the terminals 26-26 formed from the strips may be fed in a generally vertical fashiomas viewed in FIG. 2, into engagement with the associated dielectric body 23.

From there, each one of the strips 32-32 is advanced into and along an associated channel 44 in a trackway 45 on the platform 43 (see FIG. 2). For purposes of this description, it will now be convenient to discuss the portions of the left half of the apparatus 30 as viewed in FIG. 2. It should be appreciated that the apparatus 30 is essentially symmetrical about an axis extending midway between the plug-receiving cavities 34-34 and then rearwardly through a point midway between the two groups of rolls 36-36.

At the initiation of each cycle of operation, each one of the channels 44-44 is aligned with an associated one of the grooves 28-28 of the dielectric body 23 into which the terminals 26-26 are to be inserted (see FIG. 3). One end of the trackway 45 is cantilevered out from and pivotally connected to a pin 46 attached to and upstanding from the platform 43. The other end of the trackway 45 is received in an opening 47 of a reciprocally moveable shearing assembly, designated generally by the numeral 51. The pivotal mounting of the trackway 45 permits the shearing assembly to be moved reciprocally without bending the trackway. In this waythe miniature, fragile strips'32-32 of partially formed terminals may be constantly provided with support within associated ones of the channels 44-44 without becoming bound therein because of deformed paths. Y

As is shown in FIGS. 3 and 4, the facilities 31 for advancing thestrips 32-32 of the terminals 26-26 includes an air cylinder 52 having a piston rod 53 extending therefrom and through a block 54. In FIG. 4, the piston rod 53 is shown in an extended condition. The block 54 is attached to a housing 56 which partially encloses and is fixedly attached to the trackway 45. As is shown in FIG. 3, a pawl 57having a toothed end 58 is mounted pivotally on a shaft 59 connected to the housing 56. The pawl 57 is biased in a counter-clockwise direction by a wire spring 61 wrapped about the shaft 59 and extending into engagement with a pin 62.

Additionally, a second housing 66 is mounted about the trackway 45 between the housing 56 and the shearing assembly 51. However, unlike the housing 56, which is fixedly attached to the trackway 45, the housing 66'is mounted slidably thereon. Also, a pawl 67 having a toothed end 68 is mounted pivotally on a shaft 69 extending from the housing 66. The pawl 67 is biased in a counterclockwise direction by a wire spring 71 wrapped about the shaft 69 and extending into engagement with a pin 72 attached to the housing 66.

As can best be seen in FIG. 3, the pawls 57 and 67 are positioned with respect tothe trackway45 so that the pawls span transversely across the four strips 32-32. Moreover, the toothed ends 58 and 68 of the pawls 57 and 67, respectively, are designed to seat be tween adjacent ones of the tangs 27-27 of each of the partially formed terminals (see FIG. 4).

Referring again to FIG. 4, it is seen that the housing 66 has a block 76 mounted thereon. The block 76 has a stud 77 extending to the right therefrom, as viewed in FIG. 4, and aligned with the piston rod 53. An adjusting bolt 78 extends from the opposite side of the block 76 and is coaxial with the stud 77. The adjusting bolt 78 may be turned into or out of the block 76 to space the block closer to or further from a stop 79 positioned within the terminal-forming and insertion facilities 33.

The block 76 is constantly biased to the right, as

viewed in FIG. 4, toward the block-54 such that the stud 77 is constantly in engagement with the piston rod 53. This is accomplished by providing a tension spring 81 connected at the ends thereof to the housings 56 and 66 (see FIG. 4). 1

TERMINAL SEVERING FACILITIES The facilities for forming the terminals 26-26 include the shearing assembly 51 which is supported in a dovetailed opening 88 in a plate 89. The plate 89 is mounted in a fixed engagement with a die block 91 mounted to a frame 92. (see FIGS. 2 and 4). .The opening 88 in the plate 89 is such that the shearing assembly 51 may be moved therein in a direction transverse of the strips 32-32 to sever the leading portions therefrom.

It will be recalled thatthe extent of the indexing of the strips 32-32 is determined by the engagement. of the bolt 78 with the stop 79. As can be seen in FIG. 4, the stop 79 is attached to the die block 91 and extends through an opening in the plate 89.

The shearing assembly 51 hasan insert 93 received in an opening 94 therein (see FIGS. 5 and 6). The insert 93 is held within the opening 94 by a bolt 95. The insert 93 is formed'to provide a plurality of openings each of which is designed to receive an associated one of .thestrips 32-32 of the partially formed terminals.

It should be appreciated from the study of FIGS. 3,

4 and 6 that the insert 93 and opening 94 in shearing assembly 51 are contoured to cooperate with the openings 34-34 to receive the dielectric bodies 23-23.

'The opening 94 in the shearing assembly 51 and one surface of the insert 93 are stepped to form a recess 97. When the dielectric body ,23 is inserted into the opening 34, the cut-off ledge 29 is received in the recess 97 whilethe front face of the housing 21 engages a face 98 of the insert 93 (see FIG. 9A).

The insert 93 is formed with an opening 101 therethrough. (see FIG. 6). The opening 101 is formed so as to provide a plurality of spaced fins 102-102 extending into the opening froma top surface thereof (see FIG. 5). The fins 102-102 each have a width essentially equal to the thickness of one of the strips 32-32 of partially formed terminals 26-26.

As can be seen in FIG. 5, ashearing blade 103 is positioned in the opening 101 between each of the fins 102-102 and between end ones of the fins and the walls of the opening. The blades 103-103 are maintained spaced apart along the bottom portions thereof by spacer plates 104-104 interposed therebetween. As will become readily apparent, the blades 103-103 are used to separate leading portions of the strips 32-32 to form successive groups of the terminals 26-26.

The blades 103-103 and the spacer plates 104-104 are maintained within the insert 93 by the walls of the opening 101 and the adjacent face of the die block 91. Since the shearing assembly 51 is mounted slidably in the dovetailed opening 88 in the plate 89 which is bolted to the die block 91, the blades 103-103 and the spacer plates 104-104 cannot unintentionally become removed from the opening 101.

The spacer plates 104-104 each has a thickness essentially equal to the thickness of the associated aligned fins 102-102. Moreover, and as can best be seen in FIG. 6, the spacer plates 104-104 are dimensioned so that a top surface 106 thereof is coplanar with the bottom surface of each of the channels 44-44 of the associated trackway 45. In this way, the blades 103-103, the spacer plates 104-104 and the bottom surface of the fins 102-102 cooperate to provide a plurality of spaced passageways 107-107 through which leading portions of the strips 32-32 are advanced. The lower edges of the trips, 32-32 are in engagement with the surfaces 106-106 of the spacer plates 104-104.

The shearing assembly 51 is designed to facilitate maintenance of the walls of the passageways 107-107. The insert 93 is mounted in the opening 94 of the shearing assembly 51 so that. the insert may be extended past a front face 108 of the assembly by turning adjusting bolts 109-109. In this way, as the edges of the shearing blades 103-103 become worn, the bolts 109-109 may be turned to move a front face 111 of the insert beyond the front face 108 of the shearing assembly 51. In the alternative, shims (not shown) may be placed behind the insert 93 to cause the front face 111 of the insert to extend beyond the front face 108 of the shearing assembly 51. Then the entire shearing assembly 51 may be mounted in a grinding machine (not shown) and the front face 111 of the insert 93 ground down to provide the blades 103-103 with freshly ground cutting edges for separating the leading portions of the strips 32-32.

Each of the shearing assemblies 51-51 associated with one of the assembly positions is mounted slidably INSERTION FACILITIES mined plane. The plane is defined by the direction of the movement of the shearing assembly 51 and by the to be moved reciprocally by an air cylinder 116 (see FIG. 2). Referring now to FIG. 3 wherein there is shown the left hand one of the assembly positions of FIG. 2, it is seen that the shearing assembly 51 is connected to the air cylinder 116 by a piston rod 117. In

this way, with the leading portion of the strips 32-32 extended through the openings in the insert 93, the air cylinder 116 may be operated to move the shearing as sembly 51 laterally of the strips and thereby shear the leading portions at the interconnecting strips 37-37 from the repetitively configured strips 32-32 to form the terminals. It should be appreciated that the movement involved to effect the separation is very slight, on the order of 20 mils.

As can be appreciated, the movement of the shearing assembly 51 would be impeded if provisions were not made for permitting a slight movement of the trackway 45 supporting the strips 32-32. The pivotal mounting of the trackway 45 about the pin 46 provides this freedom of movement as the shearing assembly 51 is shifted laterally by the air cylinder 116. The entire assemblage of the trackway 45 and housings 56 and 66 with associated elements may be pivoted about the pin 46 and hence not impede the movement of the shearing assembly 51.

direction of the path of travel of the strips 32-32.

In order to accomplish this, the strips 32-32 of the terminals 26-26 are advanced through the passageways 107-107 in the shearing assembly 51 into associated grooves 121 -1-21 formed in the die block 91 and then into engagement with a wall 123 of the die block (see FIGS. 3 and 7A). At this time, and as can be viewed in FIGS. 3 and 4, each of the leading repetitively configured portions of the terminal strips 32-32 is supported along the leading edge thereof and also along the adjoining flat faces of the terminals 26-26.

The grooves 121-121 associated with each of the plug-receiving cavities 34-34 are formed by spacing five inserts 126-126 in an opening 127 (see FIG. 7A)

in the die block 91. The inserts 126-126 are maintained within the opening 127 by a keeper128 (see FIG. 4). In this way, the precision size of the grooves 121-121 may be easily maintained. The inserts 126-126 may be removed and machined or easily replaced. v

The relative positions of the shearing assembly 51 and the die block 91 in an aligned unoperated condition are best shown in FIG. 7A. As can be seen, the passageways 107-107' are aligned with the grooves 121-121 in the die block 91. These are also aligned with the channels 44-44 in the trackway 45.

The actuation of the cylinder 116 moves the shearing assembly 51 with respect to the die block 91 (see FIG. 713) to accomplish a dual function. The blades 103-103 sever the portions 37-37 interconnecting the repetitively configured strips 32-32 to form terminals 26-26. Secondly, the movement of the shearing assembly 51 is sufficient to cover the grooves 121-121 formed in the die block 91 such that the newly formed ones of the terminals 26-26 received in each of the grooves 121-121 is now completely enclosed about the periphery thereof asfdefined hereinbefore. This condition is shown in FIG...7B wherein the aligned channels 44-44 and passageways 107-107 are now misaligned with the groove 1241-121 in the die block 91. The enclosed periphery includes the leading edge thereof, the two flat adjoining faces and then along the newly formed edges adjacent the remaining portions of the strips 32-32 (see FIG. 7B and FIG. 8).

The newly formed ones of the terminals 26-26 are aligned with associated ones of the grooves 28-28 in the dielectric body 23 of the connector now positioned in the cavity 34-above the grooves 121-121. Moreover a bottom edge of each one of the terminals 26-26 is aligned with a blade-like insertion ram 131 (see FIGS. 3, 4 and 8) which is mounted slidably within the associated groove 12]. formed in the die block 91.

Each of the insertion rams 131-131 is attached to a slotted head 132 which is connected to a piston rod 133 of an air cylinder 134 which is used to move reciprocally the insertion rams .131-131 within the associated grooves 121-121. The insertion rams 131-131 are dimensioned so as to fit snugly, but slidably, within the associated ones of the grooves 121-121. In this way, there is no possibility of the insertion rams 121-121 overriding one of the miniature type terminals 26-26 and causing a malfunction of the equipmentor damage to the terminals. v

As can best be seen in FIGS. 3 and 4, the topmo edge of each of the insertion rams 131-131 is deliberately slightly below the bottom edges of the stop 32-32. Or, relative to the shearing assembly 51, the topmost edge of each of the rams 131-131 is slightly below the surface 106 of the spacer plates 104-104 in the insert 93. In this way, there is no possibility that the topmost edges of the rams 131-131 will protrude above the bottoms of the trackways 45-45 and sur-.

faces 106-106 of the spacer plates 104-104 to inter.- fere with the indexing of the strips 32-32.

OPERATION In the first step embodying the principles of this invention, an operator grasps simultaneously two cords 24-24 having dielectric bodies 23-23 pre-attached to each end thereof. Then the operator inserts one of the partially completed plugs -20into each one of the two openings 34-34 formed in a front face of the terminal forming and insertion apparatus 33. Then the operator causes the air cylinder 52 to be operated to extend the piston rod 53 therefrom. As the piston rod 53 is extended, the rod urges the stud 77 and hence the block 76 and attached housing 66 to the left to the position as viewed in FIG. 4, thereby extending the spring 81 between the housings 56 and 66.

As the housing 66 is moved to the left as shown in FIG. 4, the pawl 67 urges the four strips 32-32 associated therewith to the left until the bolt 78 engages the stop 79. At that time, the leading edges of the leading portions of each of the strips 32-32 are in engagement with the face 123 of the die block 91. As this occurs, the contact tangs 27-27 of each of the partially formed terminals 26-26 of the four strips 32-32 ride under the toothed end 58 of the pawl 57. It will be observed from FIG. 3 that at this time of the cycle, the tops of the insertion rams '131-131 are slightly below the bottom edges of the strips 32-32.

Then, the cylinder 52 is operated to return the piston rod 53 to the right, as viewed in FIG. 4. The return of the piston rod 53 tends to disengage the piston rod from the stud 77. However, the spring 81 causes the block 76 and the housing 66 and the pawl 68 to be moved to the right, as viewed in FIG. 4, thereby disengaging the bolt 78 from the stop 79. This causes the toothed end 68 of the pawl 67 to ride over the contact tangs 27-27 of the strips 32-32 until the stud 77 abuts the exposed end of the piston rod 53 in a retracted position.

It should be appreciated that as the piston rod 53 is withdrawn to the right, the pawl 57 which is in registration with ones of the terminals 26-26 prevents retrograde movement of the strips 32-32. Of course, when the indexing pawl 67 is moved to the left to advance the strips 32-32, the pawl 57 simply moves pivotally in a clockwise direction to permit the strips to be advanced to the left.

With the leading edge of the leading repetitively configured portions of the terminal strips 32-32 in engagementwith the face 123, the two adjoining faces of each one of the leading portions is supported laterally by the walls of the associated ones of the grooves 121-121 (see FIGS. 3 and 4). h

Then the operator causes the operation of the shearing assembly 51 to sever the interconnecting portions 37-37 and thereupon complete the formation of the miniature terminals 26-26. This is accomplished by causing the operation of the air cylinder 116 to move the shearing assembly 51 approximately 20 mils to the right as shown in FIG. 3. (also see FIG. 7B). This causes the front faces of the blades 103-103 of the die insert 93 to shear through the interconnecting portions 37-37 of the strips 32-32 to separate the leading portion of the strips from the remaining portion thereof. This results in the formation of two sets of four terminals 26-26 which are to be inserted in the dielectric bodies 23-23 which have the grooves 28-28 thereof aligned with the grooves 121-121 of die block 91. The newly formed trailing edge of each one of the set of terminals 26-26 along the plane of separation causes each of the strips 32-32 to have a newly-formed leading edge.

The shearing assembly 51 not only forms the terminals 26-26 but has the dual function of simultaneously completing the lateral support for the terminals 26-26 formed thereby. This is accomplished by covering the grooves 121-121 to support the newly formed trailing edges of the terminals 26-26 and complete the enclosure around the periphery of the terminals, as viewed in FIGS. 73 and 8. This facilitates the insertion of the terminals 26-26 into'the dielectric body 23 and prevents any buckling of the terminals or misalignment with the miniature grooves 28-28 into which they are to be inserted. At this time, the relative positions of the shearing assembly 51 and the die block 91 are asshown in FIGS. 78 and 8.

Next, the operator causes the apparatus 33 to func tion to insert the terminals 26-26 in each of the dielectric bodies 23-23. It will be recalled that from the beginning of each cycle and up to this time, the topnewly formed terminals 26-26.

Then the rams 131-131 are moved further to move the terminals 26-26 along associated ones of the grooves 12l-l2l. upwardly andthen into the terminalreceiving grooves 28-28 of the dielectric body 23. As the insertion rams 131-131 move the terminals 26-26 into the grooves 28-28, the barbs of the terminals embed themselves along the walls of the dielectric part 21 to anchor the terminals within the grooves. Then the cylinder 134 is cycled to withdraw downwardly the insertion blades 131-131 prior to the intermittent advance of the terminals strips 32-32 for the next cycle of terminal forming and insertion.

It should be appreciated that the support of the terminals 26-26 here is along the leading edge, the two flat adjoining faces of the terminals, and along the newly formed edge of the terminals formed from the strips 32-32. Then the insertion rams 131-131 are moved into engagement with the bottom edge of the terminals 26-26 for insertion into the dielectric body 23. The rams 131-131 engage those portions of the terminals 2626 which, in use of the connector 20, will make electrical engagement with corresponding external components within the telephone set.

The methods and apparatus of this invention could just as well be used to provide support for the terminals 26-26 along a leading edge, along the top-most portion of the tangs 27-27 of the terminals and along the bottom side thereof. Then the shearing assembly 51 modified for movement in a direction extending between the tangs 27-27 and the lower edge of the terminals 2626 is activated to shear the interconnecting portions 37-37. Then, the insertion tools could be used to engage one of the flat faces of the terminals 26-26 and then move the terminals along a groove or passageway into engagement with an electrical connector. In this embodiment, the periphery along which each of the terminals 26-26 is supported prior to insertion is defined by a plane determined by the paths of travel of the strips 32-32 and the direction of relative movement between the shearing assembly 51 and the die block 91.

Of course, the strips 32-32 could be advanced through the shearing assembly 51 and into the die block 91 in the same orientation as they are unwound from the rolls 36-36. The shearing assembly 51 is then modified to be moved transverse of the strips 32-32 to shear the interconnecting portions 37-37.

The departure from the prior art resides in the movement of the strips 32-32 through the uniquely constructed shearing assembly 51 which is used to separate successive leading portions of the strips to form terminals. The shearing assembly 51 not only forms the terminals 26-26 which are to be inserted, but has the dual function of completing the support of the terminals 2626 along selected surfaces to facilitate the insertion thereof without distorting the terminals. The selected surfaces are determined by first determining the surfaces which are to be engaged by the rams 131-131 for insertion into the dielectric part 21.

[t is to be understood that the above-described arrangements are simply illustrative of the principles of a the invention. Other arrangements may bedevised by those skilled in the art which will embody theprinciples of the invention and fall within the spirit and scope thereof.

What is claimed is:

l. A method of assembling a blade-like terminal with a dielectric body to form an electrical connector, which includes the steps of:

advancing a repetitively configured elongated metaI- lic material along a predetermined path to move a leading portion thereof through a passageway opening to one surface and then into a groove opening to another surface adjacent the one surface such that the leading portion is supported along a leading edge and two adjoining faces thereof;

separating the leading portion of the elongated mate rial from the subsequent portions thereof and between ones of the repetitive configurations to form a terminal having a trailing edge opposite the leading edge while covering the groove to complete the support of the terminal around the periphery thereof as defined by the leading and trailing edges and the two adjoining faces;

aligning the dielectric body with the groove;

engaging an unsupported surface of the terminal which faces into the groove; and

moving the terminal from the groove and into assembled relationship with the aligned dielectric body.

2. An apparatus for assembling blade-like terminals into terminal-receiving openings formed in a dielectric body to engage the terminals electrically with conductors of a cord preconnected to the dielectric body to form an electrical connector, which comprises:

means for feeding a plurality of strips of repetitively configured elongated metallic material; means for receiving leading portions of the elongated material to partially support laterally leading portions along leading edges and two adjoining faces thereof;

means mounted for movement relative to the receiving means and through which the leading portion of the repetitively configured elongated material is fed for separating the leading portions of the elongated materials from the remainder of the elongated materials between ones of the repetitive configurations to form a plurality of terminals and for completing the .support of the leading portions along the lines of separation when relative movement has been caused to occur between the separating means and the receiving means;

means for causing relative movement between the separating means and the receiving means to form the plurality of terminals and to support the terminals along the lines of separation;

means receiving the dielectric body for holding the dielectric body with the terminal-receiving openings thereof aligned with the terminals supported in the receiving means; and

means operated subsequent to the formation of the terminals and engaging an exposed surface of each of the terminals for moving the terminals into associated ones of the terminal-receiving openings and assembled relation with the dielectric body.

3. The apparatus of claim 2, wherein the receiving means is a die block having a plurality of open-ended grooves formed therein, each of the grooves being aligned with and communicating with an associated one of the terminal-receiving openings in the dielectric body in the holding means.

4. The apparatus of claim 3, wherein the receiving means is stationary and the separating means is a shearing assembly mounted for movement in a direction extending between the two adjoining faces of the leading portions of each of the strips.

5. The apparatus of claim 4, wherein the shearing assembly includes an insert having passageways therethrough aligned with the grooves to permit the strips to be fed therethrough, the insert being moveable beyond a front face of the shearing assembly to facilitate machining thereof to maintain sharp-edged entrances to the openings thereof.

6. The apparatus of claim 4, wherein the feeding means includes a trackway for supporting the strips of terminals.

7. The apparatus of claim 6, wherein the trackway 8. A method of assembling a terminal to a block of insulating material having a groove therein, which includes the steps of:

advancing a strip of partially formed terminals con- I nected end to end to move a leading one thereof into an insertion position;

confining a leading edge and two side surfaces of the leading one of the terminals;

positioning a block of insulating material to align a groove formed therein with the leading one of the terminals;

shearing the leading one of the partially formed terminals from the strip to define and produce an individual terminal having a trailing edge; while confining the leading one of the terminals along the trailing edge thereof to support completely laterally the terminal and provide a laterally closed path of movement for the terminal; and

engaging a free edge of the leading one of the terminals and then moving the terminal along the path into the aligned groove. g 9. An apparatus for assembling a terminal to a block of insulating material having a groove therein, which includes:

means for advancing a strip of partially formed terminals connected end to end to move a leading one thereof into an insertion position; means for confining a leading edge and two side sur faces of the leading one of the terminals; means for positioning a block of insulating material to align a groove formed therein with the leading one of the terminals; means for shearing the leading one of the partially formed terminals from the strip to define and produce an individual terminal having a trailing edge;

means for confining the leading one of the terminals along the trailing edge thereof to support completely laterally the terminal and provide a laterally closed path of movement for the terminal; and

means-for engaging a free edge of the leading one of the terminals and for then moving the terminal along the path into the aligned groove. 

1. A method of assembling a blade-like terminal with a dielectric body to form an electrical connector, which includes the steps of: advancing a repetitively configured elongated metallic material along a predetermined path to move a leading portion thereof through a passageway opening to one surface and then into a groove opening to another surface adjacent the one surface such that the leading portion is supported along a leading edge and two adjoining faces thereof; separating the leading portion of the elongated material from the subsequent portions thereof and between ones of the repetitive configurations to form a terminal having a trailing edge opposite the leading edge while covering the groove to complete the support of the terminal around the periphery thereof as defined by the leading and trailing edges and the two adjoining faces; aligning the dielectric body with the groove; engaging an unsupported surface of the terminal which faces into the groove; and moving the terminal from the groove and into assembled relationship with the aligned dielectric body.
 2. An apparatus for assembling blade-like terminals into terminal-receiving openings formed in a dielectric body to engage the terminals electrically with conductors of a cord preconnected to the dielectric body to form an electrical connector, which comprises: means for feeding a plurality of strips of repetitively configured elongated metallic material; means for receiving leading portions of the elongated material to partially support laterally leading portions along leading edges and two adjoining faces thereof; means mounteD for movement relative to the receiving means and through which the leading portion of the repetitively configured elongated material is fed for separating the leading portions of the elongated materials from the remainder of the elongated materials between ones of the repetitive configurations to form a plurality of terminals and for completing the support of the leading portions along the lines of separation when relative movement has been caused to occur between the separating means and the receiving means; means for causing relative movement between the separating means and the receiving means to form the plurality of terminals and to support the terminals along the lines of separation; means receiving the dielectric body for holding the dielectric body with the terminal-receiving openings thereof aligned with the terminals supported in the receiving means; and means operated subsequent to the formation of the terminals and engaging an exposed surface of each of the terminals for moving the terminals into associated ones of the terminal-receiving openings and assembled relation with the dielectric body.
 3. The apparatus of claim 2, wherein the receiving means is a die block having a plurality of open-ended grooves formed therein, each of the grooves being aligned with and communicating with an associated one of the terminal-receiving openings in the dielectric body in the holding means.
 4. The apparatus of claim 3, wherein the receiving means is stationary and the separating means is a shearing assembly mounted for movement in a direction extending between the two adjoining faces of the leading portions of each of the strips.
 5. The apparatus of claim 4, wherein the shearing assembly includes an insert having passageways therethrough aligned with the grooves to permit the strips to be fed therethrough, the insert being moveable beyond a front face of the shearing assembly to facilitate machining thereof to maintain sharp-edged entrances to the openings thereof.
 6. The apparatus of claim 4, wherein the feeding means includes a trackway for supporting the strips of terminals.
 7. The apparatus of claim 6, wherein the trackway has one end supported by the separating means and the other end mounted pivotally to permit the trackway to be moved with the separating means.
 8. A method of assembling a terminal to a block of insulating material having a groove therein, which includes the steps of: advancing a strip of partially formed terminals connected end to end to move a leading one thereof into an insertion position; confining a leading edge and two side surfaces of the leading one of the terminals; positioning a block of insulating material to align a groove formed therein with the leading one of the terminals; shearing the leading one of the partially formed terminals from the strip to define and produce an individual terminal having a trailing edge; while confining the leading one of the terminals along the trailing edge thereof to support completely laterally the terminal and provide a laterally closed path of movement for the terminal; and engaging a free edge of the leading one of the terminals and then moving the terminal along the path into the aligned groove.
 9. An apparatus for assembling a terminal to a block of insulating material having a groove therein, which includes: means for advancing a strip of partially formed terminals connected end to end to move a leading one thereof into an insertion position; means for confining a leading edge and two side surfaces of the leading one of the terminals; means for positioning a block of insulating material to align a groove formed therein with the leading one of the terminals; means for shearing the leading one of the partially formed terminals from the strip to define and produce an individual terminal having a trailing edge; means for confining the leading one of the terminals along the trailing edge thereof to suppOrt completely laterally the terminal and provide a laterally closed path of movement for the terminal; and means for engaging a free edge of the leading one of the terminals and for then moving the terminal along the path into the aligned groove. 